Method and apparatus for forming headed blanks



April 26, 1966 H. F. PHIPARD, JR 3,247,533

METHOD AND APPARATUS FOR FORMING HEADED BLANKS Filed NOV. 13, 1963 4 Sheets-Sheet l 92 fi0 54 i; 4% Q INVENTOR.

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METHOD AND APPARATUS FOR FORMING HEADED BLANKS Filed Nov. 13, 1963 4 Sheets-Sheet 2 5 F 5 g3 68 9 45 70 e2 9 4 44 i; J06

April 26, 1966 H. F. PHIPARD, JR 3,247,533

METHOD AND APPARATUS FOR FORMING HEADED BLANKS Filed Nov. 13, 1965 4 Sheets-Sheet 5 V///// r W INVENTOR/ April 1966 H. F. PHIPARD, JR 3,247,533

METHOD AND APPARATUS FOR FORMING HEADED BLANKS Filed Nov. 15, 1963 v 4 sheetS-sheei 4.

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United States Patent 3,247,533 METHGD AND APPARATUS FOR FORMING BEADED BLANKS Harvey F. Phipard, Jr., South Dartmouth, Mass. (459 Mount Pleasant St., New Bedford, Mass.) Filed Nov. 13, 1963, Ser. No. 323,338 6 Claims. (Cl. 12.5)

The present invention relates to a novel method and apparatus for producing blanks for screws, bolts and the like more specifically to a novel method and apparatus for forming enlarged heads on such blanks.

Heretofore suggested methods and apparatus for forming blanks of the type contemplated herein, have contemplated cooperable punch and die means for progressively forming heads on blanks at successive stages and transfer finger mechanisms and the like for advancing the blanks from one station to the next. Apparatus including such transfer finger mechanisms are relatively complicated and expensive and difficulty is frequently encountered in adjusting the apparatus so that the transfer mechanisms operate in properly timed relationship with movable portions of the punch and die means.

it is an important object of the present invention to provide a novel method and apparatus for forming blanks for screws, bolts and the like having enlargements or heads thereon, which method and apparatus are relatively simplified and more economical and efficient.

A more specific object of the present invention is to provide a novel method and apparatus for forming blanks of the above-described type whereby the blanks are advanced to successive work stations without the aid of complicated transfer fingers or other similar mechanisms.

Still another object of the present invention is to provide novel cooperable punch and die means which may be readily installed in existing machines for forming heads or enlargements on blanks at successive stages rapidly and efficiently and without the aid of separate transfer mechanisms for advancing the blank from one location to the next.

Other objects and advantages of the present invention will become apparent from the following description and the accompanying drawings wherein;

FIG. 1 is a simplified fragmentary elevational view showing a portion of an apparatus incorporating features of the present invention;

FIG. 2 is a fragmentary elevational view taken generally along line 22 in FIG. 1;

FIG. 3 is a fragmentary elevationar view taken generally along line 3-3 in FIG. 1; F168. 4 through '12 are enlarged fragmentary partial sectional views showing successive positions of cooperable punch and die means constructed in accordance with features of the present invention during operation of the apparatus; and I FIGS. 13 through 18 show a modified form of the invention and correspond to FIGS. 5, 7 and 912 respec tively. 1

Referring now more specifically to the drawings wherein like parts are designated by the same numerals throughout the various figures, an apparatus 20 incorporating features of the present invention is shown in simplified form and in part in PlGS. 1-3. In general,, the apparatus comprises a (he means 22 and cooperable punch means 2-4 constructed in accordance with features of the present invention and described in detail below. The die means 22 is mounted on a fixed frame 26 of a machine having a reciprocable ram 23 actuated by a crank member 35). The ram 3,247,533 Patented Apr. 26, 1966 The punch means 24 is mounted on the slide member 32 for movement therewith. The machine comprising the frame 26, the ram 28, the slide member 32 and related elements may be of various known constructions and need not be shown nor described in detail herein. It suffices to state that the machine is such that the punch means 24 is reciprocated toward and away from the die means and also transversely of the die means as will be described more in detail below.

Referring more specifically to FlGS. 4-12, it is seen that the die means 22 comprises a first die 36 mounted in a die holder or block 38. A second die 46 is secured in the die holder adjacent the die 36. The die 36 is formed with a bore 42 therein into which a portion of a screw blank is adapted to be extruded as will be described below. The die 36 is counterbored at 44 for receiving a main body of a screw blank which will be restrained by a restriction 46 between the bore portions 42 and 44.

The die 40 is formed with a bore 43 and counterbore 58 similar in diameter to the bore 42 and counterbc-re 44 and having a shoulder 52 therebetween similar to the shoulder 46. However, the shoulder 52 is axially offset from the shoulder 46 toward the cooperable punch means a distance sufiicient so that the length of the bore 50 is substantially less than the length of a blank to be processed for enabling an outer end portion of the blank to be forged into an enlarged head portion. In this embodiment the die 4% is provided with an annular recess 54 around an outer end of the counterbore 50 for aiding in the desired forming of an enlarged head portion on a blank.

The punch means 24 comprises a first extrusion punch member 56 secured in a holder 58 mounted on the slide 32. The punch 56 includes an elongated portion 60 adapted at least partially to enter the counterbore 44 of the die 36 for extruding a blank in the die.

in accordance with an important feature of the present invention the punch means 24 further include a Spring biased member 62 which serves not only to aid in partially forming an enlarged head on a blank but which also serves to transfer a blank from one workstation to a succeeding work station. The spring biased punch member 62 has an internal bore 64 having a diameter similar to that of the counterbore 44 in the die member 36 so that the bore 64 is adapted to receive an end portion of a blank which has been extruded in the die member 36. The bore 64 merges with a conical enlarged recess 66 at the outer end of the punch member 62, which conical recess accommodates an initial swaging and enlargement of a head portion of a blank when the punch 62 is working with the die 40 but not when it is cooperating with the die 36.

The punch member 62 is axially slidably disposed in a bore 68 in a block 70 fixed in the holder 58. The bore 68 has an enlarged inner end portion 72 for slidably receiving a radially extending flange 74 on the punch member 62, which flange is cooperable with an annular shoulder 76 on the block 70 for limiting outward move-' ment of the punch member 62. A compression spring 78 is disposed within the bore portion 72 for biasingthe punch member 62 toward its outermost position shown in FIG. 4. A fixed pin-like abutment or punch element 80 is disposed within the bore .bore 64 of the spring biased member 62 for limiting movement of a blank into the; bore 64 and for forcing a blank into the die member 40 82 has a recess 84 in an outer end thereof, which recess is provided with the desired configuration of the finished head of a blank to be processed.

The machine 20 :is provided with means for feeding a continuous length of wire 86 to a position adjacent the die 36 as shown in FIG. 3. This means may be of known construction and need not be described in detail. The machine further includes a reciprocable cut-off blade 88 and a cooperable clamping element 94 for severing a blank 2 of predetermined length from the wire. The shearing blade 88 and cooperable clamping element 90 are also mounted and actuated in a known manner for carrying the blank 92 to a position in alignment with the die 36 as shown in FIG. 4. When the blank has been positioned in this manner, continued operation of the machine causes the cooperable die and punch means to be actuated relative to each other through the series of positions shown in FIGS. 4-12.

In the position shown in FIG. 4, the punch 60 and spring biased member 62 are respectively axially aligned with the dies 36 and 40. Operation of the ram 28 toward the right as viewed in FIGS. 1 and 4, causes the punch members to be moved into position shown in FIG. 5 so that the punch element 60 serves to force the blank 92 into the counterbore 44 and cause an end portion 93 of the blank to be extruded into the bore 4-2 to provide blank configuration 92a. The crank arm 39 then serves to retract the ram 28 and the lever 34 is actuated for shifting the slide member 32 upwardly for aligning the spring biased punch 62 and the finishing punch 82 with the dies 36 and 40 respectively as shown in FIG. 6.

When the parts are in position as shown in FIG. 6, continued operation of the apparatus causes the ram to move to the position shown in FIG. 7, in which position the spring biased punch 62 engages the outer end of the die 36 and is partially collapsed into the bore 72 against the action of the compression spring. At the same time a knockout pin 96 which extends through the bore 42 of the die 36 is actuated for shifting the blank 92a axially from the bore 44 and into the bore 64 of the punch 62. The knockout pin 96 is actuated in a known manner such as by pivoted lever 98 (see FIG. 1). This actuating means may be of conventional construction and it suffices to state that the lever 98 is operated in timed relationship with the movement of the punches for ejecting the blank 92a from the die 38 in the manner described.

It will be observed that after the blank is partially inserted into the punch 62, the ram 2 8 is moved through the partially withdrawn position shown in FIG. 8. In the partially withdrawn position shown in FIG. 8, it will be noted that the spring biased punch 62 maintains engagement with the face of the die 38 so as to insure proper positioning of the blank 92a within the spring during movement of the slide 32 for positioning the punch 62 in alignment with the die 40 as a transfer device for aligning the workpiece or blank with the die 40 as shown in FIG. 9.

During operation of the apparatus from the position shown in FIG. 8 to a position shown in FIG. 9, another blank 95 is severed from the length of wire stock material and advanced into alignment with the die 36. Upon advancement of the ram toward the right for moving the punches from the position shown in FIG. 9 to a position shown in FIG. 10, the punch 62 cooperates with the die 40 for upsetting an end portion 100 of the blank 92:: to provide an intermediate enlarged configuration having a cylindrical section conforming to the recess 54 in the die 40 and a frustoconical portion conforming to the frustoconical recess 66 in the punch 62. At the same time the blank 95 is forced into the extruding die 36 and formed into the configuration 95a.

During movement of the punches from the position shown in FIG. 9 to the position shown in FIG. 10, the blank 92a enters the die 40 prior to any work being accomplished on the blank. In other words the construction is such as to insure entry of the blank into the die before the blank is subjected to swaging forces. Continued movement of the punches causes the member 62 to the axially collapsed and the blank to be swaged or forged between the die 40 and the punch element 88 into configuration 92!) as shown in FIG. 10.

The punches are then withdrawn from the position shown in FIG. 10 and the slide 32 is actuated for aligning the punch 82 with the die 40 and shown in FIG. l l. During this movement of the punches it will be noted that the partially formed blank 92b will be retained in the die 40. At the same time, the blank 95a will be retained in the die 36 for subsequent transfer to the spring biased punch 62. Then movement of the punch toward the right to the position shown in FIG. 12 causes the punch 82 to cooperate with the die 40 for finishing the blank 9211 into the configuration 92c and providing a head portion 102 and intermediate flange 104 thereon as shown in FIGS. 1 and 12.

After the finshing operation, the blank 92a is ejected from the die 4! as shown in FIG. 1 by an ejecter pin 106 which is suitably actuated in a known manner in timed relationship with the remainder of the apparatus by means including a lever 10-8. As previously indicated the ejecter means may be of known construction and need not be described in detail. Of course, the previously described series of steps for forming the blank 92 is repeated for completing the blank 95 and for forming successive blanks cut from a length of stock material.

From the above description it is seen that .the apparatus is of extremely simple construction and may be operated efficiently and at high speeds. More specifically it is seen that successive blanks are formed in a plurality of extruding and swaging steps by a plurality of cooperable die and punch means, and the blanks are moved from one work station to the next without the aid of relatively complicated and expensive transfer devices.

In FIGS. 13 through 18 a slightly modified form of the present invention is shown. The structure of this embodiment is similar to the structure described above as indicated by the application of identical reference numerals with the sufiix d added to corresponding elements. This embodiment differs primarily in that the punch member 62a is fixed and rigidly supported rather than resiliently supported as is the corresponding element of the previously described embodiment. This change simplifies the structure and is satisfactory for many installations. In addition, this embodiment illustrates the manner in which the dies and punches may be modified to provide a screw blank having a different configuration. In this connection it will be noted that the die 40d is formed with a substantially uniform diameter for 48d for forming a screw shank of substantially uniform diameter throughout its length and the punch member 82d is provided with a rounded recess 84d for forming the screw blank with a rounded head.

The method of forming the screw blank by means of the modified apparatus shown in 'FIGS. 13 through 18 is the same as the method described above. More specifically, a blank 92 is initially aligned with the die 36:! whereupon the apparatus is actuated to the position shown in FIG. 1 3 for forming the blank into the configuration 92d. Then the dies and punches are relatively shifted to the position shown in FIG. 14 and moved toward each other so that the blank 92d is inserted into the punch 620', Then the apparatus is actuated to position the dies and punches as shown in "FIG. 15 so that the blank 92d is in alignment with the die 40d and another blank 95a. is positioned in alignment with the die 36d. Subsequently, the dies and punches are moved together as shown in FIG. 16 for forming the blank 92d to the con'fiuration 92c? while the blank 95 is formed into the configuration 9511. Subsequently the apparatus is moved through the position shown in FIGS. 17 and 18 so that the blank 92a is formed into the enemas configuration 92 while the blank 95d is transferred to the punch member 62d. Of course, the finished blank 92 is then discharged from the apparatus and the cycle is repeated.

While the preferred embodiment of the present invention has been shown and described herein, it is obvious that many structural details may be changed without departing from the spirit and scope of the appended claims.

The invention is claimed as follows:

1. In an apparatus for working and forming blanks, op posed sets comprising first and second punches and first and second dies, means for relatively actuating said punches and dies toward and away from each other and for alternately aligning said first and second punches with said first and second dies respectively and said second punch with said first die, said first punch and first die complementing each other and working a blank therebetween, said first die including bore means for receiving and retaining a blank, said second punch and said first die being relatively constructed for avoiding the working of a blank therebetween and retained in said bore means of said first die, said second punch including bore means for receiving and retaining a blank ejected from said first die and serving to transfer said blank into alignment with said second die, and said second punch and said second die complementing each other for working and forming a blank therebetween.

2. In an apparatus for forming blanks, the combination comprising opposed sets of first and second punches and first and second dies, means for relatively actuating said punches and dies toward and away from each other and for alternately aligning said first and second punches with said first and second dies and said second punch with said first die, said first die including means for receiving and retaining a blank, said second punch and said first die being relatively constructed for avoiding working of a blank therebetween and initially retained by said first die, said second punch including an axially resiliently yieldable member having axially extending aperture means therein for receiving and retaining a blank ejected from said first die and serving to transfer said blank into alignment with such second die, said second punch and said second die complementing each other for working a blank therebetween, and said yieldable member of said second punch projecting for positioning a blank retained thereby in association with said second die during relative movement of said second punch and second die together prior to the working of the blank.

3. In an apparatus as defined in claim 2, pin means extending into said apertured punch member and providing a fixed abutment engageable with a blank between said punch member and said second die, said punch member being axially collapsible relative to said pin means during working of said blank.

4. In an apparatus for forming workpieces such as headed blanks and the like, first means including first and second dies having parallel axes, second means including first, second and third punches having parallel axes, means supporting said first and second means for relatively moving said punches and said dies axially toward and away from each other and for alternately aligning said first and second punches with said first and second dies respectively and said second and third punches with said first and second dies respectively, said first punch and first die complementing each other for working a blank therebet-ween, said first die having means for retaining a blank after being Worked by said first punch and die, said second punch and said first die being relatively constructed for avoiding Working of the blank when they are in alignment, said second punch including means for receiving and retaining a blank ejected from said first die when the second punch and the first die are aligned, said second punch serving to transfer the blank from said first die into alignment with said second die, said second punch and second die complementing each other for working a blank therebetween and partially forming an enlargement on said blank, said second die including means for retaining the blank after being worked upon by said second punch for subsequent alignment with said third punch, and said third punch and second die complementing each other for working a blank therebetween and further forming said enlargement.

5. An apparatus, as defined in claim 4, wherein said second punch includes a resiliently axially yieldably supported member having axially extending aperture means gaging a blank with a first die and partially working the blank with and retaining the blank in said first die, then adv-ancing a punch toward said first die and transferring said blank to said punch and simultaneously avoiding working of the blank between said punch and said first die, then retaining said blank by said punch and transferring said punch and the blank retained thereby into alignment with a second die, subsequently relatively moving said punch and said second die toward each other and further working the blank therebetween, transferring the blank from said punch to said second die, and then engaging said blank in said second die with another punch and further working said blank.

References Cited by the Examiner UNITED STATES PATENTS 2,114,420 4/1938 Freter 10-27 ANDREW R. JUHASZ, Primary Examiner, 

1. IN AN APPARATUS FOR WORKING AND FORMING BLANKS, OPPOSED SETS COMPRISING FIRST AND SECOND PUNCHES AND FIRST AND SECOND DIES, MEANS FOR RELATIVELY ACTUATING SAID PUNCHES AND DIES TOWARD AND AWAY FROM EACH OTHER AND FOR ALTERNATELY ALIGNING SAID FIRST AND SECOND PUNCHES WITH SAID FIRST AND SECOND DIES RESPECTIVELY AND SAID SECOND PUNCH WITH SAID FIRST DIE, SAID FIRST PUNCH AND FIRST DIE COMPLEMENTING EACH OTHER AND WORKING A BLANK THEREBETWEEN, SAID FIRST DIE INCLUDING BORE MEANS FOR RECEIVING AND RETAINING CONSTRUCTED FOR AVOIDING THE WORKING OF A BEING RELATIVELY CONSTRUCTED FOR AVOIDING THE WORKING OF A BLANK THEREBETWEEN AND RETAINED IN SAID BORE MEANS OF SAID FIRST DIE, SAID SECOND PUNCH INCLUDING BORE MEANS FOR RECEIVING AND RETAINING A BLANK EJECTED FROM SAID FIRST DIE AND SERVING TO TRANSFER SAID BLANK INTO ALIGNMENT WITH SAID SECOND DIE, AND SAID SECOND PUNCH AND SAID SECOND DIE COMPLEMENTING EACH OTHER FOR WORKING AND FORMING A BLANK THEREBETWEEN. 